Wet friction plate and wet multiple disc clutch device provided with wet friction plate

ABSTRACT

Provided are a wet friction plate and a wet multiplate clutch device including the wet friction plates capable of improving the performance for discharging lubricant oil adhering to surfaces of friction members. A wet friction plate includes oil grooves and friction members on a flat plate annular core metal. At a surface of a porous layer of the friction member, a friction slide surface and lubricant oil recessed portions are formed. The lubricant oil recessed portion has no sharp portion in a pointed shape, such as a corner portion, and is formed with a smooth continuous surface. The multiple lubricant oil recessed portions depressed in a recessed shape with respect to the friction slide surface are formed. In the porous layer, hollow portions are formed to have the same formation rate between a portion forming the friction slide surface and a portion forming the lubricant oil recessed portion.

TECHNICAL FIELD

The present invention relates to a wet friction plate used in lubricantoil. Specifically, the present invention relates to a wet friction platesuitable for a wet multiplate clutch device arranged between a motor anda drive target to be rotatably driven by the motor to transmit driveforce of the motor to the drive target or block such transmission.Moreover, the present invention relates to a wet multiplate clutchdevice including the wet friction plates.

BACKGROUND ART

Typically, on a vehicle such as a four-wheeled vehicle or a two-wheeledvehicle, a wet multiplate clutch device is mounted for transmittingrotary drive force of a motor such as an engine to a drive target suchas a wheel or block such transmission. Generally, the wet multiplateclutch device transmits the rotary drive force or blocks suchtransmission in such a manner that two plates arranged facing each otherin lubricant oil are pressed against each other.

In this case, one of two plates includes a wet friction plate having afriction member provided along a circumferential direction on a surfaceof a flat plate annular core metal. For example, Patent Literature 1below discloses a wet friction member (hereinafter referred to as a “wetfriction plate”) having a papermaking groove (hereinafter referred to asa “lubricant oil recessed portion”) depressed in a recessed shape andformed at a surface of a friction member. With this configuration, inthe wet friction plate, lubricant oil adhering to a surface of the wetfriction plate is easily discharged. Thus, drag torque can be reduced.

CITATION LIST Patent Literature

-   PATENT LITERATURE 1: JP-A-2007-263203

However, in the wet friction plate described in Patent Literature 1, asupport layer of the lubricant oil recessed portion into which thelubricant oil enters is compressed and deformed by pressing or cuttingfor forming the lubricant oil recessed portion. Thus, tendency showsthat lubricant oil discharge performance is degraded. For this reason,in the typical wet friction plate, specifically in a case where thelubricant oil is at a low temperature or a case where the pressure ofcontact between the wet friction plate and a clutch plate is low, aproblem that it is difficult to discharge the lubricant oil is caused.

The present invention copes with the above-described problem. An objectof the present invention is to provide a wet friction plate capable ofimproving the performance for discharging lubricant oil adhering to asurface of a friction member and a wet multiplate clutch deviceincluding the wet friction plates.

SUMMARY OF INVENTION

In order to achieve the object described above, a feature of the presentinvention is a wet friction plate which includes: a friction memberincluding a friction slide surface and multiple lubricant oil recessedportions depressed in a recessed shape with respect to the frictionslide surface, the friction slide surface and the lubricant oil recessedportions being formed at a surface of a porous layer having multiplehollow portions; and a core metal formed in a flat plate annular shapeand provided with the friction member along a circumferential direction.The friction member is configured such that a surface of each lubricantoil recessed portion has no sharp portion in a pointed shape, such as acorner portion, and formed with a smooth continuous surface and aformation rate of the hollow portions in the porous layer forming thelubricant oil recessed portions and a formation rate of the hollowportions in the porous layer forming the friction slide surface areidentical to each other.

According to the feature of the present invention having such aconfiguration, a wet friction plate has no sharp portions in a pointedshape, such as corner portions, at the surfaces of the lubricant oilrecessed portions. That is, the surface of the lubricant oil recessedportion is formed with the smooth continuous surface. In addition, theporous layer forming the lubricant oil recessed portion and the porouslayer forming the friction slide surface are formed to have the sameformation rate of the hollow portion. Thus, lubricant oil penetrationand discharge performance of the porous layer is the same between thefriction slide surface and the lubricant oil recessed portion. Thus, theperformance for discharging lubricant oil adhering to a surface of thefriction member can be improved.

Note that the same formation rate of the hollow portion between theporous layer forming the lubricant oil recessed portion and the porouslayer forming the friction slide surface does not mean only perfectmatch of the formation rate of the hollow portion between these layers.A case where a difference in the formation rate of the hollow portionbetween the layers falls within such a range (e.g., a difference ofequal to or less than ±10%) that a difference in the lubricant oilpenetration and discharge performance between the layers falls within apredetermined range (e.g., a difference of equal to or less than ±10%)taken as the substantially same penetration and discharge performance isalso included in the same formation rate of the hollow portion.Moreover, the smooth continuous surface forming the surface of thelubricant oil recessed portion may be a lubricant oil recessed portionsurface including an inclined surface having a linearly-extending flatsurface. Note that the surface of the lubricant oil recessed portionpreferably includes the curved surface depressed in the recessed shape.

Further, another feature of the present invention is that each lubricantoil recessed portion is configured such that at least one of twosections in directions perpendicular to each other as viewed in plane isformed in an arc shape with one curvature.

According to another feature of the present invention having such aconfiguration, in the wet friction plate, the lubricant oil recessedportion is formed such that the section along at least one of twodirections perpendicular to each other as viewed in plane has the arcshape with one curvature. Thus, the lubricant oil recessed portion canbe easily formed.

Further, still another feature of the present invention is that, in thewet friction plate, each lubricant oil recessed portion is formed in along hole shape or an oval shape as viewed in plane.

According to still another feature of the present invention having sucha configuration, in the wet friction plate, the lubricant oil recessedportion is formed in the bottomed long hole shape or oval shape asviewed in plane. Thus, the lubricant oil recessed portion can be formedwhile a necessary friction contact area can be ensured without locallycausing a great missing portion of the friction slide surface at thefriction slide surface.

Further, still another feature of the present invention is that, in thewet friction plate, each lubricant oil recessed portion is formed tolinearly extend, and adjacent ones of the lubricant oil recessedportions are formed in directions perpendicular to each other.

According to still another feature of the present invention having sucha configuration, the wet friction plate is formed such that thelubricant oil recessed portion linearly extends. In addition, adjacentones of the lubricant oil recessed portions are formed in the directionsperpendicular to each other. Thus, weakening of the durability of thefriction member in a specific direction can be prevented, and uniformdurability can be ensured. Moreover, the lubricant oil recessed portionsare formed in directions crossing a rotary drive direction of the wetfriction plate. This can improve friction resistance. In addition, thelubricant oil recessed portion is formed to extend outwardly in a radialdirection of the wet friction plate. Thus, the lubricant oil dischargeperformance by the centrifugal force can be ensured.

Still another feature of the present invention is that in the wetfriction plate, the lubricant oil recessed portions are formed withmultiple types of depths.

According to still another feature of the present invention having sucha configuration, in the wet friction plate, the lubricant oil recessedportions are formed with the multiple types of depths. Thus, in a casewhere abrasion of the friction member is accelerated and the entirethickness of the friction member decreases, the lubricant oil recessedportions with small depths are brought into a state close todisappearance. Thus, degradation of the durability of the frictionmember can be reduced. In this case, a similar advantageous effect canbe expected in such a manner that the lubricant oil recessed portions ofthe wet friction plate are formed with multiple types of groove widthsinstead of or in addition to formation of the lubricant oil recessedportions with the multiple types of depths.

The present invention can be implemented not only as the inventionrelating to the wet friction plate, but also can be implemented as theinvention relating to a wet multiplate clutch including the wet frictionplates and the method for manufacturing the wet friction plate.

Specifically, it is preferred that a wet multiplate clutch deviceincludes: an opposing plate arranged facing a drive plate to berotatably driven by a motor through a clearance and lubricant oil. It isalso preferred that the opposing plate and the drive plate contact eachother or separate from each other to transmit rotary drive force betweenthe opposing plate and the drive plate or block transmission of therotary drive force, and at least one of the drive plate or the opposingplate is the wet friction plate according to any one of claims 1 to 5.It can be expected that the wet multiplate clutch device having such aconfiguration provides features and advantageous effects similar tothose of the wet friction plate.

The method for manufacturing the wet friction plate is the method formanufacturing a wet friction plate including a friction member having afriction slide surface and multiple lubricant oil recessed portionsdepressed in a recessed shape with respect to the friction slidesurface, the friction slide surface and the lubricant oil recessedportions being formed at a surface of a porous layer having multiplehollow portions, and a core metal formed in a flat plate annular shapeand provided with the friction member along a circumferential direction.This method may include the original shape formation step of forming, ina sheet shape, the slurry of a raw material including a fibrous materialforming the porous layer, the water content adjustment step of reducingthe water content of the sheet-shaped raw material to equal to or lowerthan 90% and equal to or higher than 50%, the lubricant oil recessedportion formation step of pressing a lubricant oil recessed portionmolding die with a surface as a smooth continuous surface with no sharpportions in a pointed shape, such as corner portions, against thesheet-shaped raw material having the adjusted water content to form thelubricant oil recessed portions, and the drying step of reducing thewater content of the sheet-shaped raw material having the formedlubricant oil recessed portions to equal to or lower than 10%. Accordingto the wet friction plate manufacturing method having such aconfiguration, the wet friction plate can be manufactured.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a sectional view of an entire configuration of a wetmultiplate clutch device including wet friction plates according to oneembodiment of the present invention;

FIG. 2 is a schematic plan view of an outer appearance of the wetfriction plate according to one embodiment of the present invention, thewet friction plate being assembled in the wet multiplate clutch deviceillustrated in FIG. 1 ;

FIG. 3 is image data obtained in such a manner that an image of thecross section of a friction member forming the wet friction plateillustrated in FIG. 2 is captured by a scanning electron microscope;

FIGS. 4A to 4C schematically illustrate the lubricant oil recessedportion at the friction member forming the wet friction plateillustrated in FIG. 2 , FIG. 4A being a plan view of the lubricant oilrecessed portion, FIG. 4B being a cross-sectional view of the lubricantoil recessed portion, and FIG. 4C being a longitudinal sectional view ofthe lubricant oil recessed portion;

FIGS. 5A and 5B are image data obtained in such a manner that image datatrimmed from the image data illustrated in FIG. 3 within trimming framesTF1, TF2 is binarized, FIG. 5A illustrating a porous layer right below afriction slide surface and FIG. 5B illustrating a porous layer rightbelow the lubricant oil recessed portion;

FIG. 6 is a bar graph showing, for each of the friction slide surfaceand the lubricant oil recessed portion, a formation rate of a hollowportion in the friction member illustrated in FIGS. 5A and 5B and aformation rate of a hollow portion in a friction member according to theprior art;

FIG. 7 is image data obtained in such a manner that an image of thecross section of the friction member according to the prior art iscaptured by the scanning electron microscope;

FIGS. 8A and 8B are image data obtained in such a manner that image datatrimmed from the image data illustrated in FIG. 7 within trimming framesTF1, TF2 is binarized, FIG. 8A illustrating a porous layer right below afriction slide surface and FIG. 8B illustrating a porous layer rightbelow a lubricant oil recessed portion;

FIG. 9 is a schematic view for describing the main steps ofmanufacturing the wet friction plate and the friction member illustratedin FIG. 2 ;

FIG. 10 is a schematic partially-enlarged view of an externalconfiguration of a lubricant oil recessed portion molding die attachedto press rollers illustrated in FIG. 9 ;

FIG. 11 is a partial plan view of an external configuration of a wetfriction plate according to a variation of the present invention;

FIG. 12 is a partial plan view of an external configuration of a wetfriction plate according to another variation of the present invention;

FIG. 13 is a partial plan view of an external configuration of a wetfriction plate according to still another variation of the presentinvention; and

FIG. 14 is a partial plan view of an external configuration of a wetfriction plate according to still another variation of the presentinvention.

DESCRIPTION OF EMBODIMENTS

Hereinafter, one embodiment of a wet friction plate, a wet multiplateclutch device including the wet friction plates, and the method formanufacturing the wet friction plate according to the present inventionwill be described with reference to the drawings. FIG. 1 is a schematicsectional view of an entire configuration of a wet multiplate clutchdevice 100 including wet friction plates 200 according to the presentinvention. Note that for the sake of easy understanding of the presentinvention, each figure as a reference in the present specificationschematically illustrates the configuration of the invention by, e.g.,exaggerating some components. Thus, in some cases, the dimensions ofeach component, a ratio between components or the like. in the figuresmight be different from actual dimensions, ratios or the like. The wetmultiplate clutch device 100 is a mechanical device configured totransmit drive force of an engine (not shown) as a motor of atwo-wheeled vehicle (a motorcycle) to a wheel (not shown) as a drivetarget or block such transmission. The wet multiplate clutch device 100is arranged between the engine and a transmission (not shown).

(Configuration of Wet Multiplate Clutch Device 100)

The wet multiplate clutch device 100 includes an aluminum alloy housing101. The housing 101 is a member formed in a bottomed cylindrical shapeand forming part of a housing of the wet multiplate clutch device 100.An input gear 102 is, with a rivet 102 b, fixed to a left side surfaceof the housing 101 as viewed in the figure through a torque damper 102a. The input gear 102 is rotatably driven by engaging with a not-showndrive gear to be rotatably driven by drive of the engine. On an innerperipheral surface of the housing 101, each of multiple (eight in thepresent embodiment) clutch plates 103 is, by spline fitting, held alongan axial direction of the housing 101 in a state in which the clutchplates 103 are displaceable and rotatable integrally with the housing101.

The clutch plate 103 is a flat plate annular component to be pressedagainst the later-described wet friction plate 200. The clutch plate 103is formed in such a manner that a thin plate member made of a SPCC(cold-rolled steel plate) material is punched in an annular shape. Alater-described not-shown oil groove having a depth of several μm toseveral tens of μm for holding lubricant oil is formed at each sidesurface (front and back surfaces) of the clutch plate 103. For thepurpose of improving abrasion resistance, surface hardening treatment isperformed for each side surface (the front and back surfaces) of theclutch plate 103 at which the oil groove is formed. Note that suchsurface hardening treatment does not directly relate to the presentinvention, and therefore, description thereof will be omitted.

A friction plate holder 104 formed in a substantially cylindrical shapeand provided concentrically with the housing 101 is arranged inside thehousing 101. At an inner peripheral surface of the friction plate holder104, many spline grooves are formed along an axial direction of thefriction plate holder 104. A shaft 105 is spline-fitted in the splinegrooves. The shaft 105 is a shaft body formed in a hollow shape, and one(the right side as viewed in the figure) end portion thereof rotatablysupports the input gear 102 and the housing 101 through a needle bearing105 a. In addition, the shaft 105 supports the spline-fitted frictionplate holder 104 in a fixed manner through a nut 105 b. That is, thefriction plate holder 104 rotates integrally with the shaft 105. On theother hand, the other (the left side as viewed in the figure) endportion of the shaft 105 is coupled to the not-shown transmission of thetwo-wheeled vehicle.

A shaft-shaped push rod 106 is arranged in a hollow portion of the shaft105. The push rod 106 penetrates the hollow portion of the shaft 105 toprotrude from one (the right side as viewed in the figure) end portionof the shaft 105. The side (the left side as viewed in the figure) ofthe push rod 106 opposite to the end portion protruding from one (theright side as viewed in the figure) end portion of the shaft 105 iscoupled to a not-shown clutch operation lever of the two-wheeledvehicle. By operation of the clutch operation lever, the push rod 106slides in the hollow portion of the shaft 105 along an axial directionof the shaft 105.

On an outer peripheral surface of the friction plate holder 104,adjacent ones of the multiple (seven in the present embodiment) wetfriction plates 200 sandwich the clutch plate 103. The wet frictionplate 200 is, by spline fitting, held along the axial direction of thefriction plate holder 104 in a state in which the wet friction plate 200is displaceable and rotatable integrally with the friction plate holder104.

The inside of the friction plate holder 104 is filled with apredetermined amount of lubricant oil (not shown). In addition, each ofthree tubular support rods 104 a is formed inside the friction plateholder 104 (the figure illustrates only one). The lubricant oil issupplied to among the wet friction plates 200 and the clutch plates 103.With this configuration, absorption of friction heat generated among thewet friction plates 200 and the clutch plates 103 and abrasion offriction members 210 are prevented.

Each of three tubular support rods 104 a is formed to protrude outwardly(the right side as viewed in the figure) in the axial direction of thefriction plate holder 104. A pressing cover 107 arranged at a positionconcentric with the friction plate holder 104 is assembled with thetubular support rods 104 a through a bolt 108 a, a receiving plate 108b, and a coil spring 108 c. The pressing cover 107 is formed in asubstantially discoid plate having the substantially same outer diameteras the outer diameter of the wet friction plate 200, and is pressedtoward a friction plate holder 104 side by the coil spring 108 c. Arelease bearing 107 a is provided at a position facing a right tip endportion of the push rod 106 as viewed in the figure at a center portioninside the pressing cover 107.

(Configuration of Wet Friction Plate 200)

Specifically, as illustrated in FIG. 2 , the wet friction plate 200includes oil grooves 203 and the friction members 210 provided on a flatplate annular core metal 201. The core metal 201 is a member as a baseportion of the wet friction plate 200. The core metal 201 is formed insuch a manner that a thin plate member made of a SPCC (cold-rolled steelplate) material is punched in a substantially annular shape. In thiscase, an internal-tooth spline 202 is formed at an inner peripheralportion of the core metal 201 such that the core metal 201 isspline-fitted to the friction plate holder 104.

At a side surface of the wet friction plate 200 facing the clutch plate103, i.e., a side surface of the core metal 201 facing the clutch plate103, the multiple (32 in the present embodiment) small piece-shapedfriction members 210 are provided along a circumferential direction ofthe core metal 201 through the oil grooves 203 forming clearances.

The oil groove 203 is a flow path configured to guide the lubricant oilbetween an inner peripheral edge and an outer peripheral edge of thecore metal 201 of the wet friction plate 200. In addition, the oilgroove 203 is also an oil holding portion configured to hold thelubricant oil between the wet friction plate 200 and the clutch plate103. Each oil groove 203 is formed to linearly extend between adjacentones of the multiple small piece-shaped friction members 210.

The friction member 210 improves friction force for the clutch plate103. The friction member 210 is made of a small piece-shaped papermaterial bonded along the circumferential direction of the core metal201. As illustrated in FIG. 3 , the friction member 210 includes a hardporous layer 211. The porous layer 211 is obtained in such a manner thatthermosetting resin with which a paper base material is impregnated ishardened.

In this case, the paper base material includes a filler added to atleast one of organic fibers or inorganic fibers. The organic fibers maybe made of one or more types of fibers such as wood pulp, syntheticpulp, polyester-based fibers, polyamide-based fibers, polyimide-basedfibers, modified polyvinyl alcohol fibers, polyvinyl chloride fibers,polypropylene fibers, polybenzimidazole fibers, acrylic fibers, carbonfibers, phenol fibers, nylon fibers, and cellulose fibers. Moreover, theinorganic fibers may be made of one or more types of fibers such asglass fibers, rock wool, potassium titanate fibers, ceramic fibers,silica fibers, silica-alumina fibers, kaolin fibers, bauxite fibers,kayanoid fibers, boron fibers, magnesia fibers, and metal fibers.

Moreover, the filler fulfills a function as a friction modifier and/or asolid lubricant. Such a filler may be made of one or more types ofmaterials such as barium sulfate, calcium carbonate, magnesiumcarbonate, silicon carbide, boron carbide, titanium carbide, siliconnitride, boron nitride, alumina, silica, zirconia, cashew dust, rubberdust, diatom earth, graphite, talc, kaolin, magnesium oxide, molybdenumdisulfide, nitrile rubber, acrylonitrile-butadiene rubber,styrene-butadiene rubber, silicon rubber, and fluorine-containingrubber. Further, examples of the thermosetting resin includephenol-based resin, melamine resin, epoxy resin, urea resin, andsilicone resin.

A number of hollow portions 212 are formed at the porous layer 211. Thehollow portions 212 are pore portions formed in clearances among thematerials including the paper base material and the thermosetting resin.Neither the paper base material nor the thermosetting resin is presentin the pore portions. The lubricant oil adhering to surfaces of thefriction members 210 penetrates and flows in the pore portions, or isheld in the pore portions. Many hollow portions 212 with various sizesare randomly formed inside the porous layer 211. In this case, thehollow portions 212 include hollow portions 212 opening at a surface ofthe porous layer 211 and hollow portions 212 formed inside the porouslayer 211 without opening at the surface of the porous layer 211.Moreover, the hollow portions 212 include adjacent hollow portions 212communicated with each other and adjacent hollow portions 212 notcommunicated with each other.

As illustrated in each of FIGS. 4A to 4C, a friction slide surface 213and lubricant oil recessed portions 214 are formed at the surface of theporous layer 211. The friction slide surface 213 is a portion configuredto friction-slide in contact with the clutch plate 103. The frictionslide surface 213 includes a flat surface. The lubricant oil recessedportion 214 is a portion configured to increase the friction resistanceof the friction member 210 and hold the lubricant oil. The multiplelubricant oil recessed portions 214 are depressed in a recessed shapewith respect to the friction slide surface 213. In this case, therecessed surface of each lubricant oil recessed portion 214 has no sharpportions in a pointed shape, such as corner portions. That is, therecessed surface of the lubricant oil recessed portion 214 is formedwith a smooth continuous surface.

In the present embodiment, each lubricant oil recessed portion 214 isformed in a long hole shape as viewed in plane. More specifically, thelubricant oil recessed portion 214 is formed in such a shape that in alongitudinal sectional shape along a longitudinal direction of thelubricant oil recessed portion 214, a deepest portion of the recessedportion linearly extends in the horizontal direction and both endportions of the deepest portion gently curve toward the friction slidesurface 213 and incline in a curved shape. Moreover, the lubricant oilrecessed portion 214 is formed with an arc cross-sectional shape along awidth direction perpendicular to the longitudinal direction. In thiscase, the lubricant oil recessed portions 214 include lubricant oilrecessed portions 214 formed with multiple types of sizes includingmultiple types of lengths in the longitudinal direction, lengths in thewidth direction, and depths of the deepest portion. In the presentembodiment, the lubricant oil recessed portions 214 are formed aslubricant oil recessed portions with multiple types of sizes of about1.0 to 2.0 mm in the longitudinal direction, about 0.6 to 0.7 mm in thewidth direction, and 0.25 to 0.4 mm in depth.

Of these lubricant oil recessed portions 214, adjacent lubricant oilrecessed portions 214 are formed to extend in directions perpendicularto each other through the friction slide surface 213. Of the lubricantoil recessed portions 214 adjacent to each other in the longitudinaldirection and the width direction, one lubricant oil recessed portion214 is formed to extend in a direction perpendicular to an adjacentlubricant oil recessed portion 214 in the present embodiment. That is,in the present embodiment, the lubricant oil recessed portions 214 areformed in a mesh shape across the entire surface of the friction slidesurface 213 as viewed in plane.

At the porous layer 211, the hollow portions 212 are formed with thesame formation rate between the portion forming the friction slidesurface 213 and the portion forming the lubricant oil recessed portion214. The formation rate of the hollow portion 212 as described herein isthe rate of the hollow portion 212 in a certain space in the porouslayer 211. The formation rate of the hollow portion 212 can becalculated from the amount of fluid injected into the porous layer 211by pressure injection, such as oil, mercury, or helium. Alternatively,the formation rate of the hollow portion 212 can be approximatelycalculated by image processing using a digital image obtained by imagingof the porous layer 211. Specifically, the formation rate of the hollowportion 212 can be calculated by the image processing of binarizingimages acquired by imaging of each section of the porous layer 211 rightbelow the friction slide surface 213 and the porous layer 211 rightbelow the lubricant oil recessed portion 214.

First, a worker cuts the lubricant oil recessed portion 214 of thefriction member 210 in a cross-sectional direction. Thereafter, digitalimage data (hereinafter merely referred to as “image data”) is acquiredin such a manner that the state of the cross section is imaged with apredetermined magnification (e.g., ×120) by means of a magnificationimaging device such as a scanning electron microscope (see FIG. 3 ). Inthis case, the worker captures a state image including the section ofthe friction slide surface 213 formed around the lubricant oil recessedportion 214 targeted for imaging.

Next, the worker performs, using a computer device capable of processingthe image data, such as a personal computer, trimming for image data ofa portion right below the lubricant oil recessed portion 214 and imagedata of a portion right below the friction slide surface 213 in theacquired image data within trimming frames TF1, TF2 with predeterminedsizes. In this case, the trimming frame TF1 defining the trimming areaof the image data of the portion right below the lubricant oil recessedportion 214 can be formed in a quadrangular shape as a whole. This shapehas a length of at least equal to or greater than ⅓ of the width of thelubricant oil recessed portion 214 with respect to the center positionof the portion right below the lubricant oil recessed portion 214 in thewidth direction thereof and a length of at least equal to or greaterthan 70% of the thickness of the porous layer 211 right below thelubricant oil recessed portion 214.

The trimming frame TF2 defining the trimming area of the image data ofthe portion right below the friction slide surface 213 is formed to havethe same size as that of the trimming frame TF1. In addition, thetrimming frame TF2 is arranged sufficiently apart from the lubricant oilrecessed portion 214 at the portion right below the friction slidesurface 213. In this case, the trimming frames TF1, TF2 are arranged atpositions close to each surface of the lubricant oil recessed portion214 and the friction slide surface 213. Note that in the presentembodiment, the trimming frame TF1, TF2 is formed with 330 pixels×660pixels.

Next, as illustrated in each of FIGS. 5A and 5B, the worker binarizestwo pieces of image data trimmed within the trimming frames TF1, TF2 bymeans of image processing software (a well-known computer program)capable of binarizing the image data. In this case, a threshold foraccurately converting image data of the hollow portion 212 in the imagedata into the black or the white is set to the image processingsoftware. With this configuration, the worker can acquire the binarizedimage data of the portion right below the lubricant oil recessed portion214 and the binarized image data of the portion right below the frictionslide surface 213. In the present embodiment, the hollow portion 212 isconverted into the black. In addition, the porous layer 211 other thanthe hollow portions 212 is converted into the white.

Next, the worker calculates, using image processing software (awell-known computer program) capable of calculating each area of theblack portion and the white portion in the binarized image data, thecumulative total of the area of the portion (the black portion)equivalent to the hollow portions 212 in the binarized image data. Suchtotal calculation is performed for each trimming frame TF1, TF2.

In this manner, when a difference between the total area of the hollowportions 212 within the trimming frame TF1 on the image data and thetotal area of the hollow portions 212 within the trimming frame TF2 onthe image data falls within a predetermined range, the worker determinesthat the formation rate of the hollow portion 212 is the same betweenthese portions. The difference falling within the predetermined range asdescribed herein preferably means that a difference between both totalsis equal to or less than a range of ±10%. Note that the worker can alsocheck the identicalness of the formation rate by comparison of the rateof the total area of the hollow portions 212 to the total area of thetrimming frame TF1 or the rate of the total area of the hollow portions212 to the total area of the porous layer 211 (the white portion)excluding the hollow portions 212 within the trimming frame TF1 with asimilar total area rate in the trimming frame TF2.

Verification results obtained by the inventor(s) of the presentinvention will be described herein. FIG. 6 is, for the friction member210 according to the invention of the present application and a frictionmember 90 according to the prior art, a bar graph of the cumulativevalue of the area of the hollow portions 212 obtained by the imageprocessing by binarization. The horizontal axis represents the totalarea of the hollow portions 212 for each of the friction slide surface213 and the lubricant oil recessed portion 214 in the friction member210 and the total area of hollow portions 92 for each of a frictionslide surface 93 and a lubricant oil recessed portion 94 in the frictionmember 90. Moreover, the vertical axis represents the rate of the totalarea of the hollow portions 212 to the entire area of each of thetrimming frames TF1, TF2.

As illustrated in FIG. 7 , the lubricant oil recessed portion 94 in arecessed shape is formed at the friction member 90 in such a manner thata die is pressed against a surface of a porous layer 91 having the samequality as that of the porous layer 211. In this case, at the lubricantoil recessed portion 94, a corner portion with an angle of about 120° isformed at each end portion of a bottom portion in a cross-sectionaldirection. Note that FIG. 7 shows an image of only one (the left side asviewed in the figure) of two corner portions. The non-imaged othercorner portion is formed at a right end portion of this image as viewedin the figure.

For the friction member 90, the inventor(s) of the present invention hasacquired image data by imaging of the porous layer 91 in a mannersimilar to that for the friction member 210. Thereafter, as illustratedin FIGS. 8A and 8B, the acquired image data is trimmed within trimmingframes TF1, TF2 and is binarized. Then, the inventor(s) of the presentinvention calculates, in a manner similar to that described above, thecumulative total of the area of a portion (a black portion) equivalentto the hollow portions 92 in the binarized image data. Note that fromthe image data illustrated in FIGS. 7, 8A and 8B, it can be alsoconfirmed that the porous layer 91 as a support layer forming thelubricant oil recessed portion 94 is more compressed and crushed in theupper-lower direction as viewed in the figure than the porous layer 91as a support layer forming the friction slide surface 93 in the frictionmember 90.

According to the verification results obtained by the inventor(s) of thepresent invention, the formation rate of the hollow portion 212 rightbelow the friction slide surface 213 in the friction member 210 is27.4%. The formation rate of the hollow portion 212 right below thelubricant oil recessed portion 214 is 26.1%. Moreover, the formationrate of the hollow portion 92 right below the friction slide surface 93in the friction member 90 is 28.8%. The formation rate of the hollowportion 92 right below the lubricant oil recessed portion 94 is 21.2%.Note that each of these formation rates is the average of multiplesamples.

(Manufacturing of Wet Friction Plate 200)

Next, the method for manufacturing the wet friction plate 200 configuredas described above will be described with reference to FIGS. 9 and 10 .First, the worker performs the raw material mixing step of mixing a rawmaterial. Specifically, the worker injects the raw material of the paperbase material, i.e., the organic fibers and/or the inorganic fibers, thefiller, and a flocculant, into water in a mixing tank 300, andthereafter, mixes such a material to generate the raw material in theform of slurry. Subsequently, the worker transfers the slurry of the rawmaterial in the mixing tank 300 to a papermaking tank 301 by means of apump 300 a.

Next, the worker performs a papermaking step. The papermaking stepmainly includes an original shape formation step, a water contentadjustment step, a lubricant oil recessed portion formation step, and adrying step. Specifically, the worker rotatably drives a delivery device303 including an endless belt-shaped papermaking net 302 arranged facingthe inside of the papermaking tank 301. Then, the worker delivers theraw material filtered in the form of a sheet from the inside of thepapermaking tank 301 to a pair of press rollers 305 (the original shapeformation step). The delivery device 303 includes, among the papermakingtank 301 and the press rollers 305, a water absorbing roller 304 a and asuction box 304 b. With this configuration, moisture is removed from thesheet-shaped raw material on the papermaking net 302 (the water contentadjustment step).

The press rollers 305 are components configured to form the lubricantoil recessed portions 214 at the sheet-shaped raw material on thepapermaking net 302. The press rollers 305 include a pair of rollersarranged facing each other. In this case, a lubricant oil recessedportion molding die 305 a formed of metal or resin threads woven in agrid shape as illustrated in FIG. 10 is wound around a surface of one oftwo rollers forming the press rollers 305. The press rollers 305 areprovided such that the water content (% by weight) of the sheet-shapedraw material on the path of the papermaking net 302 falls within a rangeof 90% to 50%. In the present embodiment, the press rollers 305 areprovided such that the water content (% by weight) of the sheet-shapedraw material on the path of the papermaking net 302 falls within a rangeof 60% to 50%.

Thus, after having drawn up from the papermaking tank 301, thesheet-shaped raw material adjusted to have a predetermined water contentpasses through the press rollers 305. In this manner, the friction slidesurface 213 and the lubricant oil recessed portions 214 are formed atthe surface facing the lubricant oil recessed portion molding die 305 a(the lubricant oil recessed portion formation step). In this case, thesheet-shaped raw material is adjusted to have a relatively-high watercontent. In addition, the lubricant oil recessed portion molding die 305a is formed with a smooth curved surface. This reduces the absence ofthe hollow portions 212 due to compression deformation of a portion ofthe friction member 210 pressed against the lubricant oil recessedportion molding die 305 a. Thus, a difference in the formation rate ofthe hollow portion 212 in the porous layer 211 between the frictionslide surface 213 and the lubricant oil recessed portion 214 can bereduced. Note that according to experiment by the inventor(s) of thepresent invention, the lubricant oil recessed portion molding die 305 aincludes the woven resin threads, and therefore, flexibility can be moreeasily ensured as compared to the case of including the metal threads.Moreover, compression deformation of the porous layer 211 right belowthe lubricant oil recessed portion 214 can be reduced.

Subsequently, the sheet-shaped raw material at which the friction slidesurface 213 and the lubricant oil recessed portions 214 are formedpassed through a drying device 306 including a drying roller arranged ona downstream side of the press rollers 305. In this manner, the watercontent is further decreased to 10% or lower (the drying step). In thiscase, the water content of the sheet-shaped raw material at which thefriction slide surface 213 and the lubricant oil recessed portions 214are formed is preferably equal to or higher than 3%. Thereafter, thesheet-shaped raw material is rolled up by a recovery roller 307, and thepapermaking step ends.

Next, the worker performs a hardening step. Specifically, the workerimpregnates, with the thermosetting resin, the sheet-shaped raw materialdried until the water content reaches 10% or lower. Thereafter, theworker hardens the sheet-shaped raw material while heating thesheet-shaped raw material and pressing and shaping the sheet-shaped rawmaterial. In this manner, the worker can manufacture the friction member210 including the porous layer 211 hardened in a state in which thefriction slide surface 213 and the lubricant oil recessed portions 214are formed.

Next, the worker performs the step of bonding the friction members 210.Specifically, the worker bonds, with an adhesive, small pieces of thefriction members 210 to the surface of the core metal 201 produced bymachining such as pressing at another step along the circumferentialdirection. In this case, the worker may bond the friction members 210cut in a small piece shape in advance to the core metal 201.Alternatively, the worker can cut the friction member 210 in a smallpiece shape when bonding the friction member 210 to the core metal 201.In this manner, the worker can manufacture the wet friction plate 200configured such that the small piece-shaped friction members 210 arebonded to both surfaces of the core metal 201 along the circumferentialdirection through the oil grooves 203. Note that the steps ofmanufacturing the wet friction plate 200 may include, for example,machining steps other than above and the steps of adjusting andexamining friction characteristics. Note that these steps do notdirectly relate to the present invention, and therefore, descriptionthereof will be omitted.

(Actuation of Wet Friction Plate 200)

Next, actuation of the wet friction plate 200 configured as describedabove will be described. As described above, the wet friction plates 200are, upon use, assembled in the wet multiplate clutch device 100. Thewet multiplate clutch device 100 is arranged between the engine and thetransmission of the vehicle as described above. By operation of theclutch operation lever by a driver of the vehicle, the wet multiplateclutch device 100 transmits the drive force of the engine to thetransmission, or blocks such transmission.

That is, in a case where the driver (not shown) of the vehicle operatesthe clutch operation lever (not shown) to retreat (displace to the leftside as viewed in the figure) the push rod 106, the tip end portion ofthe push rod 106 does not press the release bearing 107 a. Thus, thepressing cover 107 presses the clutch plates 103 by elastic force of thecoil spring 108 c. Accordingly, the clutch plates 103 and the wetfriction plates 200 are in a friction-coupled state. In this state, allplates are pressed against the outer peripheral surface of the frictionplate holder 104 while displacing toward a receiving portion 104 bformed in a flange shape. As a result, the drive force of the enginetransmitted to the input gear 102 is transmitted to the transmissionthrough the clutch plates 103, the wet friction plates 200, the frictionplate holder 104, and the shaft 105.

On the other hand, in a case where the driver of the vehicle operatesthe clutch operation lever (not shown) to advance (displace to the rightside as viewed in the figure) the push rod 106, the tip end portion ofthe push rod 106 presses the release bearing 107 a. Thus, the pressingcover 107 displaces to the right side as viewed in the figure againstthe elastic force of the coil spring 108 c. Then, the pressing cover 107and the clutch plates 103 are separated from each other. Accordingly,the clutch plates 103 and the wet friction plates 200 displace to apressing cover 107 side, and the state in which all plates are pressedagainst each other and coupled to each other is cancelled. Thus, allplates are separated from each other. As a result, the drive force is nolonger transmitted from the clutch plates 103 to the wet friction plates200. As a result, transmission of the drive force, which is transmittedto the input gear 102, of the engine to the transmission is blocked.

In this state in which the clutch plates 103 and the wet friction plates200 friction-contact each other, the lubricant oil present on thesurfaces of the friction members 210 of the wet friction plates 200 ispushed by the clutch plates 103. Then, part of the lubricant oil isdischarged to the outside of the friction members 210 through outer edgeportions thereof. In addition, another part of the lubricant oilpenetrates the friction members 210. In this case, the lubricant oilpenetrating the friction members 210 includes lubricant oil held in thelubricant oil recessed portions 214 and lubricant oil penetrating theporous layers 211. Part of the lubricant oil penetrating the porouslayers 211 is discharged from end surfaces of the porous layers 211 (thefriction members 210) through the hollow portions 212. In addition,another part of the lubricant oil remains in the hollow portions 212.

In this case, there are no sharp portions in the pointed shape, such asthe corner portions, at the surfaces of the lubricant oil recessedportions 214 holding the lubricant oil. That is, these surfaces areformed with the smooth continuous surfaces. In addition, theabove-described surfaces are formed such that the formation rate of thehollow portion 212 in the porous layer 211 forming the lubricant oilrecessed portion 214 and the formation rate of the hollow portion 212 inthe porous layer 211 forming the friction slide surface 213 are the sameas each other. With this configuration, a difference in lubricant oilpenetration and discharge performance of the porous layer 211 is smallbetween the friction slide surface 213 and the lubricant oil recessedportion 214 in the wet multiplate clutch device 100. Thus, theperformance for discharging the lubricant oil adhering to the surface ofthe friction member 210 is improved. Moreover, temperaturecharacteristics (cooling characteristics) and surface pressurecharacteristics can be stabilized. As a result, the durability of thefriction member 210 can be improved.

In the wet multiplate clutch device 100, when the clutch plates 103 andthe wet friction plates 200 are separated from each other, the amount oflubricant oil remaining among the clutch plates 103 and the wet frictionplates 200 is less than that in the prior art. Thus, the wet multiplateclutch device 100 can reduce a state in which the clutch plates 103 andthe wet friction plates 200 are indirectly connected to each other dueto the lubricant oil present among these plates, i.e., drag torque, uponclutch-OFF.

As can be understood from description of actuation above, according tothe above-described embodiment, there are no sharp portions in thepointed shape, such as the corner portions, at the surface of thelubricant oil recessed portion 214 of the wet friction plate 200. Thatis, such a surface is formed with the smooth continuous surface. Inaddition, the above-described surface is formed such that the formationrate of the hollow portion 212 in the porous layer 211 forming thelubricant oil recessed portion 214 and the formation rate of the hollowportion 212 in the porous layer 211 forming the friction slide surface213 are the same as each other. Thus, the lubricant oil penetration anddischarge performance of the porous layer 211 is the same between thefriction slide surface 213 and the lubricant oil recessed portion 214.Thus, the performance for discharging the lubricant oil adhering to thesurface of the friction member 210 can be improved.

Further, implementation of the present invention is not limited to theabove-described embodiment, and various changes can be made withoutdeparting from the object of the present invention. Note that in eachvariation described below, reference numerals corresponding to thoseassigned to the wet friction plate 200 are used to represent componentssimilar to those of the wet friction plate 200 in the above-describedembodiment. Moreover, description thereof will be omitted.

For example, in the above-described embodiment, the wet friction plates200 are held by the friction plate holder 104 to be rotatably drivenintegrally with the shaft 105. That is, the wet friction plate 200 isapplied as an opposing plate arranged facing the clutch plate 103 to berotatably driven by the rotary drive force of the engine and rotatablydriven integrally with the shaft 105 as an output shaft in the wetmultiplate clutch device 100. However, the wet friction plate 200 can bealso applied to the clutch plate 103 as a drive plate to be rotatablydriven by the rotary drive force of the engine.

Moreover, in the above-described embodiment, the lubricant oil recessedportion 214 is formed such that the cross-sectional shape thereof is asingle arc shape. However, it may only be required that the surface ofthe lubricant oil recessed portion 214 has no sharp portions in thepointed shape, such as the corner portions, and is formed with thesmooth continuous surface. Thus, the lubricant oil recessed portion 214may include a linear portion as included in the longitudinal section ofthe lubricant oil recessed portion 214. Alternatively, the lubricant oilrecessed portion 214 may be formed to have a curved surface with two ormore curves.

Further, in the above-described embodiment, the lubricant oil recessedportion 214 is formed in the long hole shape as viewed in plane.However, it may only be required that the surface of the lubricant oilrecessed portion 214 has no sharp portions in the pointed shape, such asthe corner portions, and is formed with the smooth continuous surface.Thus, as illustrated in FIG. 11 , the lubricant oil recessed portion 214can be formed in a dimple shape recessed in a hemispherical shape.Alternatively, the lubricant oil recessed portion 214 can be formed inan oval shape. As illustrated in FIG. 12 , the lubricant oil recessedportions 214 can be formed in shapes including the long hole shape andthe oval shape. Alternatively, as illustrated in FIG. 13 , the lubricantoil recessed portion 214 can be formed to linearly extend in a radialdirection of the core metal 201 and penetrate the friction member 210.Alternatively, the lubricant oil recessed portion 214 can be formed toextend in the circumferential direction and a tangential directioninstead of or in addition to the radial direction of the core metal 201.Alternatively, as illustrated in FIG. 14 , the lubricant oil recessedportions 214 can be formed to extend in a grid shape or a mesh shape intwo directions crossing each other. Alternatively, the lubricant oilrecessed portion 214 can be formed in a curved shape instead of or inaddition to the linear shape as viewed in the plane.

In addition, in the above-described embodiment, the lubricant oilrecessed portions 214 are formed to have the multiple types of sizesincluding the multiple types of lengths in the longitudinal direction,lengths in the width direction, and depths. However, all of thelubricant oil recessed portions 214 can be formed in the same shapes.

Moreover, at the original shape formation step of the above-describedembodiment, the endless belt-shaped papermaking net 302 is used to formthe raw material in the sheet shape extending in a band shape. However,it may only be required that the papermaking net 302 forms the rawmaterial in the sheet shape. Thus, the papermaking net 302 may be formedin a quadrangular shape or a circular shape. In this case, thepapermaking net 302 formed in the quadrangular shape or the circularshape can be housed in a bottomed tubular molding die, and can form theraw material in a quadrangular or circular sheet shape.

Further, in the above-described embodiment, the water content of thesheet-shaped raw material is adjusted to equal to or lower than 60% andequal to or higher than 50% at the water content adjustment step.However, it may only be required that at the water content adjustmentstep, the water content of the sheet-shaped raw material is adjusted toequal to or lower than 90% and equal to or higher than 50%. Preferably,such a water content is adjusted to equal to or lower than 70% and equalto or higher than 50%. With this configuration, the lubricant oilrecessed portion 214 can be easily formed with high accuracy.

In addition, in the above-described embodiment, at the lubricant oilrecessed portion formation step, the lubricant oil recessed portions 214are formed by the lubricant oil recessed portion molding die 305 aformed in a roll shape. However, at the lubricant oil recessed portionformation step, the planar lubricant oil recessed portion molding die305 a can be pressed against the raw material to form the lubricant oilrecessed portions 214.

Moreover, in the above-described embodiment, the lubricant oil recessedportion molding die 305 a includes the resin threads woven in the gridshape. However, it may only be required that the lubricant oil recessedportion molding die 305 a forms the lubricant oil recessed portions 214on the raw material. Thus, the lubricant oil recessed portion moldingdie 305 a may be made of a resin material or a metal material formed ina grid shape by processing such as injection molding. Alternatively, thelubricant oil recessed portion molding die 305 a can be formed of aresin or metal plate-shaped body having multiple recessed-raisedportions or through-holes formed for formation of the lubricant oilrecessed portions 214.

Further, in the above-described embodiment, the example where the wetfriction plate according to the present invention is applied as the wetfriction plate 200 used for the wet multiplate clutch device 100 hasbeen described. However, it may be only required that the wet frictionplate according to the present invention is a wet friction plate used inoil. In addition to the wet multiplate clutch device 100, the wetfriction plate according to the present invention can be applied as awet friction plate used for a brake device configured to put a brake onrotary motion by the motor.

LIST OF REFERENCE SIGNS

-   TF1 Trimming frame for acquiring image data of portion right below    lubricant oil recessed portion-   TF2 Trimming frame for acquiring image data of portion right below    friction slide surface-   90 Typical friction member-   91 Porous layer-   92 Hollow portion-   93 Friction slide surface-   94 Lubricant oil recessed portion-   100 Wet multiplate clutch device-   101 Housing-   102 Input gear-   102 a Torque damper-   102 b Rivet-   103 Clutch plate-   104 Friction plate holder-   104 a Tubular support rod-   105 Shaft-   105 a Needle bearing-   105 b Nut-   106 Push rod-   107 Pressing cover-   107 a Release bearing-   108 a Bolt-   108 b Receiving plate-   108 c Coil spring-   200 Wet friction plate-   201 Core metal-   202 Spline-   203 Oil groove-   210 Friction member-   211 Porous layer-   212 Hollow portion-   213 Friction slide surface-   214 Lubricant oil recessed portion-   300 Mixing tank-   300 a Pump-   301 Papermaking tank-   302 Papermaking net-   303 Delivery device-   304 a Water absorbing roller-   304 b Suction box-   305 Press roller-   305 a Lubricant oil recessed portion molding die-   306 Drying device-   307 Recovery roller

The invention claimed is:
 1. A method for manufacturing a frictionmember having a friction slide surface and multiple lubricant oilrecessed portions depressed in a recessed shape with respect to thefriction slide surface, the friction slide surface and the lubricant oilrecessed portions being formed at a surface of a porous layer havingmultiple hollow portions, said method comprising: an original shapeformation step of filtering a slurry raw material containing a papersubstrate and forming the raw material in a sheet shape; a water contentrate adjustment step of removing a water content from the sheet-shapedraw material to adjust a water content rate to 90% to 50%; a lubricantoil recessed portion formation step of pressing a lubricant oil recessedportion molding die against the sheet-shaped raw material in which thewater content rate has been adjusted to 90% to 50% to form the lubricantoil recessed portions; a drying step of removing the water content fromthe sheet-shaped raw material having the formed lubricant oil recessedportions to adjust the water content rate to 10% or less; and a curingstep of impregnating the sheet-shaped raw material in which the watercontent rate has been adjusted to 10% or less with a thermoplasticresin, wherein the lubricant oil recessed portion molding die is formedof metal threads woven in a grid shape or resin threads woven in thegrid shape.
 2. A method for manufacturing a wet friction platecomprising: the friction member comprising the friction slide surfaceand the multiple lubricant oil recessed portions depressed in therecessed shape with respect to the friction slide surface, the frictionslide surface and the lubricant oil recessed portions being formed atthe surface of the porous layer having the multiple hollow portions; anda core metal formed in a flat plate annular shape and provided with thefriction member along a circumferential direction, said methodcomprising: a bonding step of bonding the friction member manufacturedby the method for manufacturing the friction member according to claim 1to the core metal.
 3. The method for manufacturing the friction memberaccording to claim 1, wherein in the water content rate adjustment step,the water content rate is adjusted to 70% to 50%.
 4. The method formanufacturing the friction member according to claim 1, wherein in thedrying step, the water content rate is adjusted to 3% or more and 10% orless.